Method of tube setting



Nov. 21, 1950 K. c. BUGG EFAL 2,530,855

METHOD OF TUBE SETTING Filed March 25, 1 45 4 Sheets-Sheet 1 mamma r I /IJ7IIIIIIIIIIII A INVENTORS. 4% 6 ay BY f/azr/y LffarZ,

Nov. 21, 1950 K. c. BUGG ET AL 2,5 8

METHOD OF TUBE SETTING 4 Sheets-Sheet 2 Filed March 25, 1945 INVENTOR5 fzieizg C fiugg, BY flu/7:9 ill/0,2

Nov. 21, 1950 K. C, BUGG ET AL METHOD OF TUBE SETTING 4 Sheets-Sheet 5 Filed March 23, 1945 Nov. 21, 1950 K. c. BUGG ETAL METHOD OF TUBE SETTING 4 Sheets-Sheet 4 Filed March 25, 1945 Patented Nov. 21, 1950 MET-HOD or TUBE SETTING Kenly C. Bugg and Harry L. Hart, Fort Wayne, Ind; said Hart assignor to said Bugg Application March 23, 1945, Serial No. 584,406

Claims. 1

This invention pertains to methods and tools for setting members having tubular holes, such as eyelets, tubes and the like, in base members such as headers.

It is an object of this invention to provide methods for fastening tubes in headers so that there will be the least possible deformation of the tube itself, and in the hole-to-hole relation of the holes in the header.

Another object of the invention is to provide methods for cold or hot fastening tubes wherein the holding beads are formed in initial holding position and are thereafter formed into final holding position.

Another object of the invention is to fasten tubes by a method whereby the transverse axis of the holding bead is unchanged, whereby uniform beads are formed.

Another object of the invention is to hot and cold fasten tubes wherein holding beads are initially formed in the position where the final bead is to be.

Another object of the invention is to provide methods for fastening tubes to headers wherein the most favorable conditions of tension or compression are set up to hold the tube in the header.

Another object of the invention is to provide methods for fastening tubes in headers, or eyelets in base members wherein simple tools may be used which are relatively small and of light weight so that they can be readily applied to tubes, no matter to what member they are to be secured and wherein the tubes may be fastened to various members in multiple, either in parallel relation or angular relation as where radiator tubes are fastened to headers, or where structural members are fastened to angular brackets.

Another object of the invention is to provide methods for fastening tubes which contemplates first conditioning the tube in the hole as by partially expanding and pre-forming, and thereafter performing a second fastening operation which is, therefore, accomplished by the least possible the tube is done while the tube is in still a relatively loose condition with respect to the header.

Another object of the invention is to provide a method of fastening tubes, eyelets or the like to a member, wherein the tubes are placed, and then secured by one or more operations.

Another object of the invention is to fasten tubes or the like to a member wherein the tubes are mechanically secured to the member and wherein a substance is used between the tubes and member to insure that the joint is pressure and fluid tight. Y

With these and various other objects in view, the invention may consist of certain novel fea- 2 tures of construction and operation as will be more fully described and particularly pointed out in the specification, drawings and claims appended hereto.

In the drawings, which illustrate embodiments of the device and wherein like reference characters are used to designate like parts-- Figure 1 is a side elevation of a form of tool for practicing the invention, said tool being adapted for initially setting tubes or eyelets in headers or the like;

Figure 2 is an enlarged sectional elevation taken substantially in the plane as indicated by the line 2-2 of Figure 1, showing the tool in position where it has initially beaded a tube;

Figure 3 is an elevation showing a form of tool for finally securing tubes or eyelets in headers or the like;

Figure 4 is a sectional elevation showing the tool in Figure 3 in position prior to operation to finally set a tube;

Figure 5 is a sectional elevation showing the tool illustrated .in Figures 3 and 4 in position where it has finally set a tube;

Figure 6 is a fragmentary sectional elevation showing a tube prior to fastening to a pair of headers;

Figure 7 is a sectional elevation corresponding to Figure 6 showing one end of the tube in initial fastened condition to a header;

Figure 8 is a sectional elevation corresponding to Figure 7 showing one end of the header in final fastened condition;

Figure 9 is a sectional elevation showing the tube illustrated in Figures 6 to 8 inclusive, in position where one end is finally fastened and one end is initially fastened;

Figure 10 is a sectional elevation showing the tube in Figures 6 to 9 inclusive, in final fastened condition to both headers;

' Figure 11 is a sectional elevation showing a tube in initial fastened condition to a pair of spaced headers;

Figure 12 is a fragmentary sectional elevation showing one end of a tube initially secured to a header wherein a portion of the tube projects beyond the bead which is to be finally collapsed;

Figure 13 is a fragmentary sectional elevation corresponding to Figure 12. showing the tube in final fastened condition wherein the portion projecting beyond the header has been flared as the bead has collapsed;

Figure 14 is a sectional elevation corresponding I to Figure 13, wherein the portions of the tube projecting beyond the headers have not been fiareol as the beads have been collapsed to final holding condition;

Figure 15 is a fragmentary sectional elevation showing a tube in initial beaded condition with respect to a header which is formed of Alclad or the like;

Figure 16 is a fragmentary sectional elevation 3 corresponding to Figure 15, showing the tube in final secured condition to the header shown in Figure Figure 17 is a fragmentary sectional elevation showin a tube in initial secured condition to a header formed of outer relatively non-resilient material spaced by relatively resilient material such as a softer metal, rubber, or the like;

Figure 18 is a fragmentary sectional elevation corresponding to Figure 17, showing the tube in final secured condition to the laminated header;

Figure 19 is an enlarged, fragmentary sectional elevation of an initially beaded tube and showing the serrated end of the collapsing tool end hous- Figure 20 is an enlarged, fragmentary sectional elevation of the collapsed bead of the tube shown in Figure 19;

Figure 21 is an enlarged, fragmentary sectional elevation of a tube showing the disposition of the collapsed bead, unless it is controlled as shown in Figure 20;

Figures 22 and 23 are enlarged fragmentary sectional elevations of one end of a tube and header, showing steps in a modified method of setting said tubes, said figures corresponding to Figures 6 and 8 respectively; and

Figure 24 is a fragmentary sectional elevation of a modified form of housing end for the beading device illustrated in Figures 3 to 5, inclusive.

This application is a continuation-in-part of application Serial No. 503,350, filed September 22, 1943, issued as Patent No. 2,405,399 on August 6, 1946, application Serial No. 541,425, filed June 21, 1944, issued as Patent No. 2,430,554, and application Serial No. 557,774, filed October 9, 1944 and subsequently abandoned.

Referring first of all more particularly to the initial setting tool illustrated in Figures 1 and 2, said tool is particularly shown and described in said Patent No. 2,405,399. Said tool comprises a pair of handles 20 and 22 pivoted as at 24 to a housing member 26, said handles being urged to inoperative position by means of the spring 28 secured to said handles as at 30 and 32. Handles 20 and 22 are provided with the cam members 34 and 86, respectively, which engage the slidable head 38 of the tubular member 40 slidably mounted within the housing member 26.

A spring 42 is interposed between the head 38 and the flange 44 provided on the housing member 26 urging said head 38 toward the left as viewed in Figure 1, that is, urging the tool toward inoperative position. The head 46 is provided with an end portion 48 disposed on a stem 50 which is secured as by the threads 54 to the block 56 which is pivoted to the pin 24 but is not loosely connected thereto, the head 46 being provided with the cam portion 52 interposed between the end 48 and the stem 50.

The cam portion 52 is adapted to engage the fingers 58 of the outer quill member 60, said member being secured as by the threads 62 to the member 40. The member 40 is also provided with the positioning member 64 adapted to engage a header or the like, so as to properly set the beads. The fingers are provided with the spaced bead forming portions 66 and 68 shown as of a shape and spacing to form a pair of beads on each side of a header. Thus the tool illustrated in Figures 1 and 2 is adapted to form a pair of initial beads, the beads being in the form as shown particularly in Figure 7.

The tool for the final setting operation, illustrated in Figures 3 to 5 inclusive, is based on the .heat treated to impart resilience thereto.

tool shown and described in said application Serial No. 541,425 and comprises the handles I0 and I2 pivoted as by pin I5 and provided with the cams I6 and I8, respectively. The housing is provided with the spaced flanges 82 apertured for the reception of the spaced securing bolts 84, said bolts 84 being secured to the housing 86, said housing terminating in an end 88 which is in a plane substantially perpendicular to the axis of stem II8, for the purpose to be later described. The outer quill member 96 is loosely pivoted as at 92 to the pin I5 and is provided with the resilient fingers 94 provided with the locating shoulder 96, the fingers by their resilience being urged toward collapsed position, that is, urged toward their axis.

The slidable block 98 is pivoted, to the pin I5 and said block is engaged by the pin or plunger I00 mounted within the housin I02. A spring I04 is interposed between said housing and the pin I06, engaging said housing at one end as at I06 and engaging the shoulder I08 of said pin I00 at the other end, urging said pin toward the right as viewed in Figure 4 whereby the block 98 is urged toward the right. The housing I02 is secured to the assembly by means of the bolts 84 and springs I I0 are interposed between the flanges II2 of said housing I02 and the flanges 82 of the housing 80.

A hardened steel washer H4 is interposed between the fianges 82 and the housing or sleeve 86 providing a track for the cams I6 and I8. The block 98 is secured as by the threads H6 to the stem II8 of the cam operating member or head I20. The member I20 comprises the cam head I22 provided with the cam surface I24 adapted,

when moved toward the left as viewed in Figure 4, to expand the fingers 94 to the position as shown in Figure 5.

In each of the tools illustrated, the outer quill member (60 and which is provided with the beads, is preferably formed from a tubular member on which the beads or ridges (66 and 68, and 96) are disposed. The tubular member is then slit in the proper manner to form the fingers, the number of fingers being determined so that they will not be too wide and thus have to move too much metal, and will not be too narrow so that they would have a tendency to cut into the metal. The fingers are then bent inwardly toward the axis of the quill member and the quill member is The formation of these members has been described in detail in said Patents Nos. 2,405,399 and In practicing the method illustrated in Figures ,6 to 10 inclusive, the tube I26 is positioned within the holes I28 and I30 of the spaced headers I 32 and I34, it being understood that a plurality of tubes (not shown) will be fastened in adjacent holes of said headers. The tool such as shown in Figures 1 and 2 is then inserted so that the quill member 60 extends within the tube. The handles 20 and 22 are then moved toward each other causing the cams 34 and 36 to move the head 38 against the spring 42, it being understood that the end of the positioning member 64 has been placed in contact with the header I32 so that the beads will be formed at the proper positions. This movement of the handles causes the stem 50 to move the cam head 48 toward the left as viewed in Figure 4 spreading the fingers of the quill causing the initial beads I36 and I38 to be formed such as shown in Figure 7. The stem moves toward the left, inasmuch as the position- 3. ing member 34 is in abutting relation with the header audit is assumed 'that'the' header is stationary. The tool" is then permitted to returrrto its initial inoperative position by releasing the handles; whereupon spring 4 2' acts against head 38 to return the device to-inoperative-position where the head itperniitsthefingersil! to contract, whereupon the tool i s-then removed from the tube.

The tool, such-as shown in Figures 3 to 5'inclu'-- sive, is inserted into'the-bead'and the ridge 96'is moved to a position where it finds-the bead I 36: The handles iii and 1-2 are then moved toward each other causing the head I2ii to expand the fingers 9d and the bead I36 acts as. positioning means, causing the end 88 of housing 86- to engage the bead I38 and collapse it, such as shown in Figure 8, the collapsing of the bead and theslight tendency of the ridge 96 to draw thebead l36 insuring a tight joint-to be effected at the header I32. Further, while an exaggerated space is shown between the tubebetween beads, and the wall of the hole, it is understood that the tools or one of them, may'be'operated so that the fingers of the outer quill members cause the metal of the tube to spline into the wall of the hole, such as shown in said Patent No. 2,405,399. The tool, such as illustrated in Figures 1 and 2-,.is then operated to form the beads Hit" and M2,. such as shown in Figure 9;. initially setting the tube with respect to the header I34. after which the tool is removed and the tool illustrated in Figures 3 to 5 inclusive is operated to collapse the bead I42 and insure a tight joint between beads Ida! and I42 in the header I34.

This method can then be practiced to fasten the desired number of tubes into the headers and because of this method, no distortion of the metal between holes takes place, although these tubes are set tightly and spaced closely. It is understood, of course, the tubes can be set either hot or cold. It also is understood the tools may be set in multiple so that a plurality of tubes are set in each step. Further; in the case of'initially forming the beads and/or finally setting the beads after an expanding operation of the outer quill members, the tools may be slightly rotated to tend to iron out any irregularitiesof the tubes in and between the beads.

A pair of each of thetoolsmaybe used serially,

such as indicated in Figure 11, whereby the beads I36, I38, tail and M2 are simultaneously formed and simultaneously fastened.

In the case of the'tubes illustrated in Figures 12 and 13, the same methods" as above described maybe used to initially form the beads I64 and I46 of the tube I48 for securing said tube in. the aperture I58 of' the header I52, but in this case a projecting end I514 of the'tube is disposed at one side'of the header and in the final securing operation shown in Figure 13, the housing member 86 of the final tool is'provide'd with the cam end I 58 for fiaring the projecting portion I54 of the tube. This cam end I56 need not be provided, in which case the tube isfi'nall'y setasillustrated in Figure 1% by the tool shown in Figs. 3 to 5. Where the cam end I56 is used it is providedwith a shoulder I58" abutting the end' of the projection I54 to cause collapse of'the bead [4'61 The tube I til shownin Figures 15 and 16 is formed with'the beads I62 and I64 by any of the above methods, the bead I54 being collapsed to final holding position as illustrated in Figure 16 and in this case the header Iii-dis provided with thebase I67 of hardened material and the coating I68 of a softer material such as in the case o'fan hlclad header; andinflhally-"settirig the bead I 6 l it-is caused to indentthe coating I53 for'insu-ring a tightj'oint'.

In Figures 17 and 18- the tube" IHl" is formed with thebeads Ii-Zand l 'l i by any of the-methods described above, thebead IW' being collapsed w final holding condition, but in this case the header I16 is laminated'; being providedwitl'i the spaced relatively hard members Flt and I805 be tween which the relatively resilient material I 81 is disposed. This material may be of aresilient metal, rubber, or the" like, and-in the final setting of the tube, theintermediate member 182 is caused to'- flow as at Iii-l intothe hole" I86 to" tightly enga e the tube between thebe'ads;

by aiding in insuring atight joint.

Theend 83 of the outer" housing: member 86 (Figures 3 to 5') ispreferably serrated so that Where a' short tube has been secured wherein the initial outer flange is not completely formed over, as in the case of the tube shown inFigur'e 7, but israther in the position as shown in Figure 19, the serrations I87 of said memberw grip the free edge of the bead and move it t'o'final collapsed condition such" as illustrated in Figure 20.- By the use of these serrationsthere isno' tendency for the bead I88 to move to anundesirable or uncontrolledposition suchas is'illustrat'ed at Itfi in Figure-2'1.

These'methods are equally successful whether or not the tubeis set hot or cold, and'by these methods tight joints are attained without the necessity ofbrazing, though,,ofcourse; thebraz= ing step may be-use'd if desired: Further; where very thick headers are? used, the tubes may be' fastened thereto in three steps, that is; by two initial bead forming" operations and one collapsing operation.

It will be noted that the main deformation of the" tube, that is; the bead forming" operation, is accomplishedwhile the tube is" in relatively loose" condition with respect to the header, thereafter the final forming (or final securing), which is of relatively small movement, taking place. The initial forming'of the bead may be accomplished: as desired; to fasten the tube in the hole of the head'- er, and thereafter one of" the beads is collapsed; which is a relatively small operation. Also, it is contemplated that all of thetubesma'ybe' initially fastened as shown in' Figure 11', and thereafter all of said tubes can be finally fastened a'sshownin Figure 14", that is; the tubes needn'ot be initially and finally fastened serially, one by one,. but i otherwise appliedto the tubes as at I96. This material should not be soluble in oil, should' be able to stand large and small temperature changes at high and low temperatures, should" withstand high and low temperatures, and: should not harden too quickly in order to" give time from its application as at I96' to the complete fastening of the tube ends as shown in Figure 23.

Several materials have been satisfactory e's'-' pecially where aluminunr tubes are fastened" m aluminum headers, and when copper and steel are similarly fastened. Such materials as the synthetic resins sold by G. E. as Glyptals, these being known as 1201-2, and Formex. Other which have been used are: orange shellac; phenolic resins as Bakelite varnishes; lead coating alloys as white or red lead; Buna rubber compounds; as Nubein, neoprene and Duprene; cellulose compounds not corrosive; lacquers and bituminous paint.

These materials when applied and when the tube is fastened fill the interstices between the tube and header. The metal on the tube surface and within the hole of the header is microscopically rough, either slightly pitted or ridged (rifled), and by using this material a fluid and pressure tight joint is assured especially where the tubes are not all set together, where the material is hard, or where the distance between holes in the header is small so that slight deformation may take place during setting. Also in commercial production the tubes may not be perfect in shape or finish and the header holes may not be perfect.

After the material has been applied to both ends, or one end as the case may be, the steps may be taken in the methods previously described to set the ends. Or, the tool described in Figures 3 to 5, inclusive may be modified so the end of housing 80 is modified to that shown in application Serial No. 541,425, and as shown in Figure 24 wherein the end I9! is tapered as at 198 to flare the tube end as shown as 200 in Figure 23. In that case the bead 202 is formed, and elongated and the flange 200 is made.

It is to be understood that this application is not to be limited by the exact embodiments of the device shown, which are merely by way of illustration and not limitation, as various and other forms of the device will, of course, be apparent to those skilled in the art without departing from the spirit of the invention or the scope of the claims.

We claim:

1. Those steps in the method of fastening one end of a tube to a header which comprise, forming outwardly projecting beads in the tube on each side of the header, thereafter holding one head against one side of the header and collapsing the other bead against its adjacent side of the header, and flaring a portion of the tube to draw the beads one toward the other to cause the beads to tightly engage the adjacent sides of said header.

2. Those steps in the method of fastening one end of a tube to a header which comprise, forming outwardly projecting beads in the tube on each side of the header, thereafter holding the inner bead against the inside of the header, collapsing the other bead against the outside of the header, and flaring a portion of the tube to draw the beads one toward the other to cause the beads to tightly engage the adjacent sides of said header.

3. Those steps in the method of fastening one end of a, tube to a header made of an inner and outer and intermediate lamination which comprise, forming beads in the tube on each side of the header, thereafter holding one bead against one side of the header and collapsing the other head against its adjacent side of the header to cause the inner lamination to flow toward the tube and to draw the beads one toward the other to cause the beads to tightly engage the adjacent sides of said header.

4. Those steps in the method of attaching a tubular member to a perforated member which comprise inserting the tubular member through a perforation, deforming the tubular member adjacent one side of the perforated member, utilizing the deformation as positioning means for a tool to form the tube with fastening means on the opposite side of the perforated member from the deformation, and drawing the deformation and fastening means toward each other into tight engagement with the perforated member.

5. Those steps in the method of attaching a tubular member to a perforated member which comprise applying to the tubular member a noncorrosive, chemically inert coating material, which is non-soluble in the fluid to which it is subjected and is capable of withstanding high and low temperatures, inserting the tubular member through a perforation so that the coating material extends through the perforation and slightly on both sides of the perforated member, deforming the tubular member adjacent one side of the perforated member, utilizing the deformation as positioning means for a tool to form the tube with fastening means on the opposite side of the perforated member from the deformation, and drawing the deformation and fastening means toward each other into tight engagement with the perforated member, thereafter permitting the coating material to harden and dry.

KENLY C. BUGG. HARRY L. HART.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date Re. 2,237 Allen May 8, 1866 8,256 McCarty July 29, 1851 40,967 Guysling Dec. 15, 1863 69,014 Moore Sept. 1'7, 1867 370,876 Kane Oct. 4, 1887 486,984 Murphy Nov. 29, 1392 526,208 Wheeler Sept. 18, 1894 784,934 Freebury Mar. 14, 1905 318,843 McCormick Apr. 24, 1906 854,869 Brinkman May 28, 1907 943,907 Austin Dec. 21, 1909 1,026,993 Moore May 21, 1912 1,291,578 McPhail Jan. 14, 1919 1,310,287 Millet July 15, 1919 1,326,195 Hasty Dec. 30, 1919 1,440,032 Stevens Dec. 26, 1922 1,440,493 Reed Jan. 2, 1923 1,589,646 Hicks June 22, 1926 1,706,118 Hopkins Mar. 19, 1929 1,714,703 Walton May 28, 1929 1,779,323 Lacerda Oct. 21, 1930 1,955,355 Brenner Apr. 17, 1934 2,172,650 Couty Sept. 12, 1939 2,188,422 Waner Jan. 30, 1940 2,211,242 McIntosh Aug. 13, 1940 2,225,856 Buck Dec. 24, 1940 2,242,831 McIntosh May 20, 1941 2,303,416 Woods Dec. 1, 1942 FOREIGN PATENTS Number Country Date 22185 Great Britain Oct. 8, 1906 511,113 Germany Oct. 28, 1930 

